Aerosol paint composition with fungicide and sprayable aerosol composition

ABSTRACT

An aerosol paint composition includes an alkyd resin; one or more solvents; an organoclay; an anti-settling wax; a dispersing agent; one or more pigments; a drying agent; an anti-skinning agent; a fragrance; and a fungicide.

BACKGROUND OF THE INVENTION

The present invention is directed to an aerosol paint compositioncomprising a fungicide and to a sprayable aerosol composition comprisingthe aerosol paint composition.

Although paints having mildew preventing agents are known, it isdifficult to formulate a sprayable aerosol composition having afungicide. In particular, it is difficult to incorporate a fungicideinto a solvent-based aerosol composition without the fungicide becominginactive. In addition, it is difficult to incorporate a resin into asprayable aerosol composition that adheres to a wide variety ofsurfaces, especially to surfaces that have been poorly cleaned.

It is an object of the present invention to develop a sprayable aerosolcomposition containing a fungicide that can be atomized properly in acontinuous spray system, yet is thick enough to cover a substratecompletely in one coat, without sagging, running, or dripping.

SUMMARY OF THE INVENTION

The aerosol paint composition according to the present inventionincludes a resin; one or more solvents; a rheology agent; ananti-settling agent; a dispersing agent; a pigment; a drying agent; ananti-skinning agent; a fragrance; and a fungicide. According to thepresent invention, the fungicide remains active in a sprayable aerosolcomposition, the composition adheres well to poorly-cleaned surfaces.The sprayable aerosol composition may be used to provide both interiorcoatings and exterior coatings.

DETAILED DESCRIPTION OF THE INVENTION

According to the present invention, an aerosol paint compositioncomprises a resin; one or more solvents; a rheology agent; ananti-settling agent; a dispersing agent; a pigment; a drying agent; ananti-skinning agent; a fragrance; and a fungicide. The aerosol paintcomposition may also contain a filler or extender. The aerosol paintcomposition may also contain an anti-flocculation agent.

The resin in the aerosol paint composition of the present invention actsas a binder which holds the various ingredients together in ahomogeneous mix and adheres to the substrate to be coated or painted. Inembodiments, the resin may be one or more of an aromatic resin, alkydresin, acrylic resin, polyester resin, polyurethane resin, or epoxyresin. In preferred embodiments, the resin may be an alkyd resin,including modified alkyds such as vinyl toluene modified alkyd resins,acrylic modified alkyd resins, styrene modified alkyd resins,acrylic/vinyl toluene modified alkyd resins, and styrene/vinyl toluenemodified alkyd resins. The resin may be present in the aerosol paintcomposition in an amount of about 10-70% by weight, preferably about15-60% by weight, based upon the total weight of the aerosol paintcomposition.

The aerosol paint composition may contain one or more solvents. Inembodiments, the one or more solvents include, but are not limited to,an aromatic solvent, oxygenated solvent, aliphatic solvent, or mixturesthereof. In preferred embodiments, the solvent may be toluene, 150Solvent, acetone, or mixtures thereof. 150 Solvent is a mixture ofpetroleum-based solvents generally comprising aromatic petroleumdistillates (96+%) and having a flash point of about 150° F. 150 Solventis commercially available as Hi Sol 15 or Aromatic 150. The one or moresolvents may be present in the aerosol paint composition in an amount ofabout 10-50% by weight, preferably about 15-40% by weight, based uponthe total weight of the aerosol paint composition.

The aerosol paint composition also comprises a rheology agent. Suitablerheology agents may comprise organoclays, fumed silica, dehydratedcastor oil organic derivatives, English China Clay; polyamides,polyimide modified alkyds, alkylbenzene sulphonate derivatives, calciumand zinc stearates, calcium soyate, and the like. In embodiments, theorganoclay may be a clay such as bentonite, smectite, kaolin, ormontmorillonite to which organic structures have been chemically bonded.Examples include, but are not limited to, CLAYTONE® and TIXOGEL®organoclay additives available from Southern Clay Products. The rheologyagent allows the paint to form a film without sagging or dripping. Therheology agent may be present in the aerosol paint composition in anamount of about 0.1-5% by weight, preferably about 0.1-3% by weight,based upon the total weight of the aerosol paint composition.

The aerosol paint composition also comprises a dispersing agent to aidin the uniform dispersing of various pigments and/or powders intouniform particle size. The dispersing agent reduces the time required togrind pigments and/or powders. The dispersing agent also aids inmaintaining a homogenous mix over time. The dispersing agent ispreferably polymeric and may include, but is not limited to, dispersantssold under the trade names Disperbyk® (an alkylammonium salt of apolyfunctional polymer available from BYK-Chemie, USA), Anti-Terra-U (asolution of unsaturated polyamine amides and acid polymers availablefrom BYK-Chemie, USA), Solsperse® (Avecia) and EFKA (EFKA Chemicals).The dispersing agent may be present in the aerosol paint composition inan amount of about 0.2-2% by weight, preferably about 0.2-1% by weight,based upon the total weight of the aerosol paint composition.

The aerosol composition may comprise one or more anti-flocculationagents which work in conjunction with the dispersing agent to enhanceits effect. The anti-flocculation agent also reduces the chance thatdifferent colored pigments will separate from other and group togetherto form streaks or patches. In embodiments, such flocculation agentsinclude, but are not limited to, Imperial Antifloat Compound (IAF)Compound X-2280 (barium sulfate). The anti-flocculation agent may bepresent in the composition in an amount of about 0.1-2% by weight,preferably about 0.2-1% by weight, based upon the total weight of theaerosol paint composition.

The aerosol composition comprises one or more pigments to impart variouscolors and shades. Suitable pigments are well known in the art and aretypical organic pigments, inorganic pigments, or mixtures thereof.Example of such pigments include, but are not limited to, titaniumdioxide, carbon black, graphite, ceramic black, antimony sulfide, blackiron oxide, aluminum pastes, yellow iron oxide, red iron oxide, ironblue, phthalo blue and green, nickel titanate, dianisidine orange,dinitroaniline orange, imidazole orange, quinacridone red, violet andmagenta, toluidine red, molybdate orange, and the like. The pigment maybe present in the aerosol composition in an amount of about 5-50% byweight, preferably about 10-40% by weight, based upon the total weightof the aerosol composition.

The aerosol composition may comprise one or more extenders or fillers toreduce the cost and increase the opacity of the paint film. Suitablefillers may include, but are not limited to, amorphous, diatomaceous,fumed, quartz and crystalline silica, clays, aluminum silicates,magnesium aluminum silicates, talc, mica, delaminated clays, calciumcarbonates and silicates, gypsum, barium sulfate, zinc, calcium zincmolybdates, zinc oxide, phosphosilicates and borosilicates of calcium,barium and strontium, barium metaborate monohydrate, and the like. Inembodiments, the filler may be calcium carbonate such as VICRON® 15-15.The filler may be present in the aerosol composition in an amount ofabout 0-50% by weight, preferably about 5-40% by weight, based upon thetotal weight of the aerosol composition.

The aerosol paint composition comprises one or more drying agents toincrease the speed with which the resin forms a hard film (i.e., cures).Drying agents include, but are not limited to, metallic and rare earthdriers such as cobalt, calcium, potassium, barium, zinc, manganese, tin,aluminum, zirconium and vanadium napthenates, octoates, hexanates, andisodecanoates. In embodiments, the drying agent may comprise a cobaltdrier. Cobalt driers include, but are not limited to, an organic cobaltsalt such as cobalt naphthenate or cobalt octoacte. The drying agent maybe present in the aerosol paint composition in an amount of about0.05-0.5% by weight, preferably about 0.05-0.4% by weight, based uponthe total weight of the aerosol paint composition.

The aerosol paint composition may comprise one or more anti-skinningagents to inhibit the skinning or formation of a solid film at thesurface of the liquid paint while it is kept in storage (e.g., in drumsor cans). In embodiments, the anti-skinning agent may include, but isnot limited to, methyl ethyl ketoxime, o-cresol, or hydroquinone. Anexample of a commercially available anti-skinning agent is Exkin orTrokyd AntiSkin. The anti-skinning agent may be present in the aerosolpaint composition in an amount of about 0.1-0.5% by weight, preferablyabout 0.2-0.4% by weight, based upon the total weight of the aerosolpaint composition.

The aerosol paint composition may comprise one or more fragrances. Thefragrance may be used to reduce the offensive smell often associatedwith spray paint. Any desirable known scenting or fragrance types may beemployed provided that the fragrance is compatible with the otheringredients in the mixtures. Examples of scents or fragrances for use inthe present invention include, but are not limited to, citrus fragrancessuch as commercially available Citrus Fragrance Z-125-04; floralfragrances; fruit fragrances; spice fragrances; and vanilla fragrances.The fragrance may be present in the aerosol paint composition in anamount of about 0.1-3% by weight, preferably about 0.1-2% by weight,based upon the total weight of the aerosol paint composition.

The aerosol paint composition comprises one or more fungicides toinhibit the growth of mold or mildew on the surface of the paint. Inembodiments, the fungicide may comprise 3-Iodo-2-propynl butylcarbamate. The fungicide may be FUNGITROL®, commercially available fromDegussa Corporation or International Specialty Products. However,thiabendazole and diiodomethyl p-tolyl sulfone will not work in theaerosol paint composition or sprayable aerosol formulation of thepresent invention. Thus, AMICAL 48, commercially available from DowChemical Co.; THIABENDAZOLE DISPERSION W, commercially available fromLanxess Corporation; or FUNGITEX TBZ, commercially available from CIBASpecialty Chemicals are incompatible with the aerosol composition. Thefungicide may be present in the aerosol paint composition in an amountof about 0.1-3% by weight, preferably about 0.1-1% by weight, based uponthe total weight of the aerosol paint composition.

The aerosol paint composition also comprises one or more anti-settlingwaxes to prevent hard settling of the paint while it is not in use. Thepigments that are used to give color to the paint are fairly heavy andtend to settle to the bottom of any liquid medium when they are storedfor extended periods. The anti-settling wax prevents these pigments fromforming a hard, compacted, solid mass. This allows the aerosol can to beshaken and for the homogenous state of the paint mixture to be restored.In embodiments, the wax may be SUSPENO®, commercially available fromPoly-Resyn, Inc. The anti-settling wax may be present in the aerosolpaint composition in an amount of about 0.5-5% by weight, preferablyabout 1-3% by weight, based upon the total weight of the aerosol paintcomposition.

The aerosol paint composition of the present invention is a concentrateand may be combined with additional thinning solvents and propellants toobtain a sprayable aerosol formulation. In embodiments, the propellantmay comprise propane, butane, or combinations thereof. An example of thethinning solvent includes acetone and an example of the propellantincludes A-80 having a pressure of about 80 psi.

According to the present invention, different methods may be used in themanufacture of the aerosol paint composition. In embodiments, a firstmethod involves grinding the one or more pigments into the resin with ahigh-speed dispersion mixer (such as a cowles). Shading pastes may besubsequently added for color correction. A second method involvesgrinding both white and colored pigments using a high-speed mill, forexample, a sandmill. Shading pastes may be subsequently added for colorcorrection. The mixing speeds and temperatures may vary with the aerosolpaint composition and the equipment used. In embodiments, temperature ofabout 100° F. or higher may be reached due to milling and grinding. Inembodiments, mixing speeds may be up to about 10,000 rpm.

The sprayable aerosol formulation may be used with any appropriate valveand actuator. In embodiments, the valve may be model SV-77/U13 (Diptube, AD Plain; Mount cup, EPT/LAMB con; Gasket, 0.050 Butyl SV-77/92;Spring, 0.023; Body, BV assy 1×0.045 RE ⅛ inch SS Ball; Stem, 2×0.020.349Nat). The actuator may be a 35 mm actuator and overcap assembly(0.020×0.030).

The following examples are intended for illustration purposes only, andshould not be deemed to limit the scope of the invention as defined inthe appended claims. All parts, percentages, proportions, and ratios areby weight, and all temperatures are in ° F. unless otherwise indicated:

EXAMPLES

The amounts are percentages by weight, based upon the weight of thetotal aerosol paint composition.

Example 1

A alkyd resin and 150 Solvent were put into a mixing tank having aCowles Blade:

12.88 VT Alkyd Copolymer Resin 1.18 150 Solvent

The mixer was started and the following ingredients were addedindividually:

1.59 SUSPENO 201X 0.16 CLAYTONE HY 0.48 DISPERBYK-181 23.89 TiO2 23.89VICRON 15-15 3.12 Toluene

The ingredients were mixed at high speed of about 9,000 RPM for about 20minutes to a 7+ grind as measured using a Hegman grind gauge. Next, thefollowing ingredients were added individually:

13.93 VT Alkyd Copolymer Resin 0.09 6% Cobalt 0.26 EXKIN 0.34 FUNGITROL820 0.90 Citrus Fragrance Z-125-04 4.26 Acetone 13.03 Toluene

The mixture was mixed for an additional 10 minutes to form an aerosolpaint composition.

Example 2

An alkyd resin and 150 Solvent were put into a mixing tank having aCowles Blade:

2.93 VT Alkyd Copolymer Resin 0.10 150 Solvent

The mixer was started and the following ingredients were addedindividually:

0.49 BYK-181 0.49 X-2280 2.45 Yellow Iron Oxide

The ingredients were mixed at high speed of about 9,000 RPM for about 20minutes. Then, the mixture was sandmilled to a 7+ grind, and rinsemilled with the following ingredients:

0.78 VT Alkyd Copolymer Resin 0.38 Toluene

While the first tank was mixing, the following ingredients were addedinto a second mixing tank with a Cowles Blade:

11.71 VT Alkyd Copolymer Resin 1.35 150 Solvent

The mixer was started, and the following items were added individually:

0.2 TIXOGEL TE 0.10 ANTI-TERRA-U 1.96 SUSPENO 201X 13.70 TiO2 19.57VICRON 15-15

The ingredients were mixed at high speed of about 9,000 RPM for about 20minutes to a 7+ grind. When this was done for the second tank, the twotanks were combined and the following items were individually addedwhile mixing:

13.86 VT Alkyd Copolymer Resin 0.10 6% Cobalt 0.29 EXKIN 0.37 FUNGITROL820 0.88 Fragrance Z-125-04 28.31 Toluene

The mixture was mixed for an additional 10 minutes to form an aerosolpaint composition.

While the present invention has been described in connection with itspreferred forms and embodiments with a certain degree of particularity,it is to be understood and it will be apparent to those skilled in theart that the present disclosure has been made by way of example only andthat numerous changes and modifications in the details of the productsand processes may be made without departing from the true spirit andscope of the invention. Accordingly, it is intended by the appendedclaims to cover all such changes and modifications as come within thescope of the invention.

1-11. (canceled)
 12. A sprayable aerosol composition comprising anaerosol paint composition and a propellant wherein said aerosol paintcomposition comprises: about 10-70% by weight of a resin, wherein theresin is an acrylic resin, an acrylic modified alkyd resin, or anacrylic/vinyl toluene modified alkyd resin; one or more of an aromaticsolvent, an aliphatic solvent, an oxygenated solvent, or mixturesthereof; about 0.1-3% by weight of a fragrance; and about 0.1-3% byweight of 3-iodo-2-propynl butyl carbamate.
 13. A sprayable aerosolcomposition according to claim 12 wherein the resin is an acrylic resin.14. A sprayable aerosol composition according to claim 13 wherein theaerosol paint composition comprises a mixture of solvents.
 15. Asprayable aerosol composition according to claim 14 wherein the mixtureof solvents comprises aromatic solvents and an oxygenated solvent.
 16. Asprayable aerosol composition according to claim 15 wherein the mixtureof solvents includes toluene and 150 solvent in an amount of about10-50% by weight.
 17. A sprayable aerosol composition according to claim16 wherein the amount of the acrylic resin is about 15% by weight to 60%by weight, and the amount of the toluene and 150 solvent is about 15% to40% by weight, based upon the total weight of the aerosol paintcomposition.
 18. A sprayable aerosol composition according to claim 14wherein said propellant comprises propane, butane, or mixtures thereof.19. A sprayable aerosol composition according to claim 18 wherein theaerosol paint composition further comprises a thinning solventcomprising acetone.
 20. A sprayable aerosol composition according toclaim 14 wherein the aerosol paint composition further comprises about0.05-0.5% by weight of a drying agent.
 21. A sprayable aerosolcomposition according to claim 20 wherein the drying agent comprisescobalt.
 22. A sprayable aerosol composition according to claim 12wherein the aerosol paint composition further comprises about 5-50% byweight of one or more pigments.
 23. A sprayable aerosol compositionaccording to claim 13 wherein the aerosol paint composition furthercomprises about 5-50% by weight of one or more pigments.
 24. A sprayableaerosol composition according to claim 14 wherein the aerosol paintcomposition further comprises about 5-50% by weight of one or morepigments.
 25. A sprayable aerosol composition according to claim 23wherein said aerosol paint composition further comprises about 0.1-5% byweight of an organoclay; about 0.5-5% by weight of an anti-settling wax;about 0.2-2% by weight of a dispersing agent; about 0.05-0.5% by weightof a drying agent; and about 0.1-0.5% by weight of an anti-skinningagent.
 26. A sprayable aerosol composition according to claim 23,wherein said aerosol paint composition further comprises ananti-flocculation agent.
 27. A sprayable aerosol composition accordingto claim 23 wherein the aerosol paint composition comprises a mixture ofsolvents comprising aromatic solvents and an oxygenated solvent.
 28. Asprayable aerosol composition according to claim 27 wherein the mixtureof solvents includes toluene and 150 solvent in an amount of about10-50% by weight.
 29. A sprayable aerosol composition according to claim28 wherein the amount of the acrylic resin is about 15% by weight to 60%by weight, the amount of the toluene and 150 solvent is about 15% to 40%by weight, based upon the total weight of the aerosol paint composition,said propellant comprises propane, butane, or mixtures thereof, and theaerosol paint composition further comprises a thinning solventcomprising acetone.
 30. An aerosol spray system comprising an aerosolcan which comprises a valve, an actuator, and the sprayable aerosolcomposition of claim
 12. 31. An aerosol spray system comprising anaerosol can which comprises a valve, an actuator, and the sprayableaerosol composition of claim 23.